SAF P89, Service Manual

Page 1: ...XL SA20018UM en US Rev H P89 Disc Brake Axles Service Manual ...

Page 2: ... These terms are defined as follows NOTE Includes additional information to enable accurate and easy performance of procedures IMPORTANT Includes additional information that if not followed could lead to hindered product performance Used without the safety alert symbol indicates a potentially hazardous situation which if not avoided could result in property damage Indicates a potentially hazardous...

Page 3: ...h if not avoided could result in death or serious injury The wheel contact surfaces between the wheel and hub MUST NOT receive additional paint IMPORTANT The wheel contact surfaces MUST be clean smooth and free from grease Failure to keep wheel and hub contact surfaces clean and clear of foreign material could allow wheel hub separations which if not avoided could result in death or serious injury...

Page 4: ...rooves scoring or hot spots 4 Visually check the brake caliper at regular service intervals as defined by the brake caliper manufacturer s basic inspection program Refer to Section 5 of this manual for further information 5 Check the spring brake chambers to make sure the parking springs are NOT caged in the released position Be sure the dust plugs are properly installed 6 Make sure that the vent ...

Page 5: ...er of the axle tube Figure 1 4 Identification Tag The sample tag shown will help interpret the information on the SAF HOLLAND USA Inc serial number tag The model number axle body part number and serial number are listed on the tag Figure 2 Record the tag numbers below for future quick reference Axle Body Part Number ______________________________ Model Number _____________________________________ ...

Page 6: ...orq 2 4A Three Piece Axle Nut 2 5 Hub with Bearing Cups 2 5a Bearing Cup Outer 2 5b Bearing Cup Inner 2 6 Cone Bearing Outer 2 7 Wheel Studs 20 8 INTEGRAL Rotor with ABS Tone Ring 2 9 Rotor Attachment Bolts 20 ITEM DESCRIPTION QTY AXLE 10 Cone Bearing Inner 2 11 Seal Hub 2 12 ABS Sensor WABCO 2 13 Clamping Bush 2 14 Brake Caliper Left Hand Brake Caliper Right Hand 1 15 M18 x 1 5 Bolt Standard 6 16...

Page 7: ... Cups and ABS Tone Ring 2 5a Bearing Cup Outer 2 5b Bearing Cup Inner 2 6 Cone Bearing Outer 2 7 Wheel Studs 20 8 U Shaped Rotor 2 ITEM DESCRIPTION QTY AXLE 9 Rotor Attachment Bolts 20 10 Cone Bearing Inner 2 11 Seal Hub 2 12 ABS Sensor WABCO 2 13 Clamping Bush 2 14 Brake Caliper Left Hand Brake Caliper Right Hand 1 15 M18 x 1 5 Bolt Standard 6 16 M18 x 1 5 Bolt Shoulder 2 17 Brake Chamber 2 18 Br...

Page 8: ...m being installed in the wrong position Figure 4 For instructions on SBS 2220 KO brake caliper inspection and repair refer to XL AS20032RM en US which can be found at www safholland com 5 2 Knorr Bremse SK7 Caliper The Knorr Bremse SK7 Caliper has a large indentation on the forward face and no SAF logo on the rear of the caliper Figure 5 The brake pads in the SK7 caliper are the same for the inner...

Page 9: ...or severe duty applications Refer to Section 19 A quick visual inspection of the condition of the brake pads can be performed without removing the wheel 1 Compare the position of the caliper marking to the carrier marking located on the underside of the caliper unit Figure 7 a Figure 7 View A shows the positions of the two 2 markings when the brake pads are in good condition b Figure 7 View B show...

Page 10: ...IMPORTANT DO NOT use high pressure cleaners or liquid cleaners on the brake rotor If the overall wear limits for the brake rotor or brake pads are exceeded Figure 10 the rotor and pads MUST be replaced Refer to rotor replacement instructions as detailed in Section 9 For brake pad replacement refer to caliper instruction manuals identified in Section 5 For both the inner and outer pads the maximum ...

Page 11: ...e the spring brakes according to the spring brake manufacturer s instructions Remove the tire and wheel assembly to access hub and rotor 2 Remove wheels from hub using support device such as a wheel dolly Failure to support weight during installation or removal of wheels could create a crush hazard which if not avoided could result in minor to moderate injury 3 Remove the ABS sensor by following t...

Page 12: ...ndard P or N Spindle wheel nut socket remove the axle spindle nut Pro Torq by rotating the nut in a counter clockwise direction Figure 15 NOTE All axle nuts on SAF HOLLAND P89 Disc Brake Axles are right hand threaded 9 Remove the outer hub bearing from the spindle Figure 15 NOTE With the axle nut s removed it is possible to access the outer bearing DO NOT hit steel parts with a steel hammer as par...

Page 13: ...ving the head unit clean excess grease from the bearings IMPORTANT A bearing which has been removed from a vehicle should be cleaned with solvent NEVER use steam or water which will rust bearings IMPORTANT Bearings that are rusted flaked pitted or have damaged cages should be replaced It is recommended to replace all questionable bearings and ALWAYS replace the cup and cone as a matched set IMPORT...

Page 14: ... with the ABS sensor block Ensure that there is clearance provided for ABS Sensor Block Figure 19 Failure to provide clearance can cause damage to property Refer to service bulletin XL SA20031SB en US 9 2 U Shaped Rotor 1 Remove the ABS sensor by following the instructions detailed in Section 16 1 2 Remove the head unit Refer to Section 6 instructions 3 Remove the rotor from the hub using a size 1...

Page 15: ...on creating a hazard which if not avoided could result in minor to moderate injury 11 Seal Bearing and Hub Installation and Adjustment IMPORTANT DO NOT mix oil and grease wheel end lubricants All SAF HOLLAND P89 Disc Brake wheel ends can be serviced with oil or grease Before servicing the SAF HOLLAND P89 wheel end with oil all grease MUST be cleaned with appropriate solvent from the bearings and h...

Page 16: ...eel seal installation tool 1 4 turn with every hammer tap until the seal is properly seated with the metal face of the seal flush with the inner shoulder of the axle spindle Figure 24 Clean and remove any excess sealant 6 Prepare the hub Remove the old lube and thoroughly clean the hub cavity and hub bore If needed use emery cloth to remove any burrs or old bore sealant Inspect the hub bore for da...

Page 17: ...of lubricant on the I D surface of the seal NOTE DO NOT apply lubricant to the O D of the seal 11 3 Hub Installation and Bearing Adjustment 1 Gently push the head unit onto the spindle to the proper position Fill the hub cavity with lubricant until it runs over the outer bearing cup NOTE When using grease pre pack the hub cavity The grease fill amount should be to a 3 o clock and 9 o clock level T...

Page 18: ...turn to step 6 e i Install the set screw into an accessible threaded hole in the lock washer The set screw must contact the inner adjusting nut Tighten to 16 20 in lbs 1 8 2 2 N m Pro Torq axle nut Figure 31 a Use a screwdriver to carefully pry the keeper arm from the undercut groove on each side until the keeper is released b Seat the bearing Using a torque wrench tighten the nut to 200 ft lbs 27...

Page 19: ...When installing new washers the attachment bolts can interfere with the ABS sensor block Ensure that there is clearance provided for ABS Sensor Block Figure 33 Failure to provide clearance can cause damage to property Refer to service bulletin XL SA20031SB en US for ABS Sensor Block Modification Procedure 5 Check the wheel bearing end play as follows a Attach the magnetic base of a dial indicator ...

Page 20: ...support device such as a wheel dolly jack Failure to support weight during installation or removal of brake drum could create a crush hazard which if not avoided could result in minor to moderate injury Failure to uncage spring brakes in accordance with manufacturer s instructions after servicing is complete will prohibit proper brake function which could result in uneven brake system component we...

Page 21: ...der bolt Figure 37 The shoulder bolt is located at the top mounting hole whether the caliper is installed forward or rearward of the axle IMPORTANT Make sure that the brake caliper is mounted on the correct side of the axle The correct position can be identified by the lengths of the guide pins on the caliper unit The longer guide pins should be positioned on the bottom of the caliper unit when in...

Page 22: ...ount wheel s on hub One or more of the wheel nuts can be started in order to hold wheel in position 4 Tighten the top wheel nut first Apply 50 ft lbs 68 N m of torque to draw the wheel up fully against the hub 5 Install remaining wheel nuts Using sequence shown in Figure 39 tighten all wheel nuts to 50 ft lbs 68 N m of torque 6 Repeating sequence shown in Figure 39 retighten all wheel nuts to 475 ...

Page 23: ...specific hubodometer availability contact SAF HOLLAND Customer Service at 888 396 6501 16 3 Tire Inflation System SAF HOLLAND DOES NOT supply tire inflation systems However the SAF HOLLAND P89 disc brake axle can be factory equipped to be compatible with many tire inflation systems currently compatible with a North American standard six bolt hub cap This includes providing tire inflation system hu...

Page 24: ...ake Chamber 1 Pre torque both chamber nuts to 60 75 ft lbs 80 100 N m 2 For final torque tighten both chamber nuts to 130 155 ft lbs 180 210 N m 5 16 18 Bolt Hub Cap 12 16 ft lbs 16 22 N m M8 x 1 25 Bolt Dust Shield Clamp 20 25 ft lbs 27 34 N m SAF U Shaped Rotor Bolt Rotor Hub Torque all ten 10 bolts in a criss cross pattern to 190 210 ft lbs 260 285 N m Three 3 Piece Axle Nut Inner Head Unit Axl...

Page 25: ...icted Relieve restriction or obstruction or replace hoses Brake control valve restricted inoperable Repair replace control valve Brake out of adjustment Adjust brake repair or replace automatic adjustment device as necessary Damaged brake chamber Replace brake chamber Damaged brake assembly Replace or repair brake assembly Dog Tracking Axle not properly aligned Align axle Slider assembly racked or...

Page 26: ...e brake chamber Damaged brake assembly Replace or repair brake assembly Unequal brake balance or timing Repair brakes as necessary Anti Lock Brake System malfunction Refer to ABS manufacturer s service literature Excessive heat cracks in rotor Brake out of adjustment Adjust brake repair or replace automatic adjustment device as necessary Overly aggressive braking Instruct train driver in proper br...

Page 27: ...to service and after every wheel removal Continually check wheel torque every 10 000 miles 16 000 km or at the intervals indicated in the vehicle owner s manual whichever occurs first Check and adjust wheel bearing end play Pack hub bearings with fresh lubricant also after every brake lining replacement check hub bearing wear SPECIAL SERVICE CONDITIONS Vehicles with long standing periods Service a...

Page 28: ...LLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc From fifth wheel rebuild kits to suspension bushing repair kits SAF HOLLAND Original Parts are the same quality components used in the original component assembly SAF HOLLAND Original Parts are tested and designed to provide maximum performance and durability Will fits look alikes or worse yet counterfeit parts will only limit the performance potentia...